Automated ultrasonic welding of cable ties

ABSTRACT

A feedback control system for use with ultrasonic welding. A weld energy set point and/or a reference power curve are used by a controller to provide a power supply voltage set point and a power supply frequency set point for the power that is to be drawn by an ultrasonic weld generator. Information regarding the actual voltage and/or frequency of the drawn electrical power, and/or the frequency and magnitude of an ultrasonic wave transmitted from the generator to an applicator tool used to weld an object can be utilized by an estimator to estimate the weld energy dissipated at the weld site and/or generate a power curve for the welding operation. Using information from the estimator, the controller can determine adjustments for variables for the current and/or future welding operations. Further, welding may not commence until a clamping force exerted on the object satisfies a clamping force set point.

FIELD OF INVENTION

The present application relates to automated ultrasonic welding of cableties, and more particularly, to automated ultrasonic welding operationsof cable ties that employ feedback control.

BACKGROUND

Cable ties often include mechanical locking features that can secure, orfasten, the cable tie in a closed position. Such cable ties ofteninclude, at or around an end of the cable tie, a housing that isconfigured to receive insertion of the other, or tail, end of the cabletie. The tail end, among other portions, of the cable tie can includeserrations that can lockingly engage a pawl that is housed within thehousing. Thus, as the tail end is inserted into, and/or pulled throughthe housing, the engagement between the pawl and serrations on the cabletie can lockingly secure the cable tie in the closed position about anobject, such as, for example, a cable bundle. Yet, the configuration ofthe housing, which can be larger than other adjacent portions of thecable tie, can create a protrusion that can rub against, and thusdeteriorate, the adjacent insulation of a cable(s) in the cable bundle,thereby compromising the integrity of the insulation. Additionally, theexcess portion of the cable tie at the tail end that is pulled through,and extends out of, the housing can often constitute waste.

Attempts at foregoing the use of such mechanical fasteners have includedusing cable ties that are secured in a closed position about an object,including cable bundles, via ultrasonic welding. Yet, use of ultrasonicwelding is often hindered by a lack of repeatable weld quality,including, for example, repeatability with respect to consistent looptensile strength, tension around the cable bundle, and/or visualappearance. Moreover, the ability to attain repeatable weld quality can,for at least certain cable ties, be a requirement for particularmarketplace and/or regulatory requirements, including, for example,Underwriters Laboratory (UL) and International ElectrochemicalCommission (IEC) standard 62275, among other standards.

Accordingly, although various manners of fastening cable ties arecurrently available in the marketplace, further improvements arepossible to provide a means for automated ultrasonic welding of cableties.

BRIEF SUMMARY

An aspect of an embodiment of the present application is a method thatcan include determining if a clamping force being exerted by a tip of aweld horn of an applicator tool on an object that is to beultrasonically welded satisfies a clamping force set point. The methodcan also include attaining a weld energy set point for the ultrasonicwelding of the object, the weld energy set point corresponding to anaccumulated energy that is to be dissipated at a weld site of theultrasonic weld. Further, after satisfaction of the clamping force setpoint, ultrasonic welding of the object can commence, during which anultrasonic weld generator can provide an ultrasonic wave to theapplicator tool for the ultrasonic welding of the object. The method canalso include estimating the weld energy that is/was delivered to theweld site, and the ultrasonic welding of the object can cease after theestimated weld energy satisfies the weld energy set point.

Another aspect of an embodiment of the present application is a methodthat can include determining if a clamping force being exerted by a tipof a weld horn of an applicator tool on an object that is to beultrasonically welded satisfies a clamping force set point. Further, areference power curve for ultrasonic welding of the object can beattained that can correspond to an amount of power that is to be drawnby an ultrasonic weld generator as a function of time during anultrasonic welding operation to attain a predetermined weld energy setpoint, the predetermined weld energy set point corresponding to anaccumulated energy that is to be dissipated at a weld site of theultrasonic weld. The method can also include commencing, aftersatisfaction of the clamping force set point, and using powerinformation from the reference power curve, the ultrasonic weldingoperation to weld together layers of the object. Further, a shape of apower curve that is generated during the ultrasonic welding operatingcan be monitored in relation to a shape of the reference power curve,and, based at least on an evaluation of the shape of the generated powercurve with respect to the shape of the reference power curve, adetermination can be made to cease the ultrasonic welding operation.

Additionally, an aspect of an embodiment of the present application is afeedback control system for welding an object, the feedback controlsystem including an ultrasonic weld generator and an applicator tool.The applicator tool can be adapted to receive an ultrasonic wavegenerated by the ultrasonic weld generator to ultrasonically weld aportion of the object, and can include a weld horn and at least onepivotal arm. The at least one pivotal arm can have an anvil segment andbe selectively displaceable to position at which at least the portion ofthe object is located between the anvil segment and a tip of the weldhorn. Additionally, the weld horn can be displaceable to selectively,and adjustably, exert a clamping force against the portion of theobject. The system can further include a controller that can be adaptedto, using at least one of a weld energy set point and a reference powercurve, generate a signal indicating a voltage set point and a frequencyset point for an electrical power that is to be drawn by the ultrasonicwelding generator. A sensor of the system can be adapted to measure theclamping force being exerted against the portion of the object, and thecontroller can be further adapted to determine (a) if the clamping forcemeasured by the sensor satisfies a clamping force set point, (b)generate, if the clamping force does not satisfy the clamping force setpoint, a signal that adjusts a position of at least the weld hornrelative to the object so as to adjust the clamping force being exertedagainst the portion of the object, and (c) delay commencement of theobject being ultrasonically welded until the clamping force exertedagainst the portion of the object satisfies the clamping force setpoint. The system can further include an estimator that can be coupledto the ultrasonic weld generator and the controller. The estimator canbe adapted to estimate at least one of the following: (a) a weld energydissipated to a weld site at which the portion of the object is beingultrasonically welded, and (b) a shape of a power curve corresponding toan electrical power drawn by the ultrasonic weld generator during theultrasonic welding of the portion of the object. Additionally, thecontroller can be further adapted to determine, based on at least one ofthe weld energy or the power curve estimated by the estimator, whetherthe ultrasonic welding of the portion of the object is completed.

These and other aspects of the present invention will be betterunderstood in view of the drawings and following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying figureswherein like reference numerals refer to like parts throughout theseveral views.

FIG. 1 illustrates an exemplary ultrasonic welding system for fasteninga cable tie to a cable bundle according to an illustrated embodiment ofthe subject application.

FIG. 2 illustrates a representation of at least a portion of anexemplary ultrasonic welding system according to an illustratedembodiment of the subject application.

FIG. 3A illustrates an enlarged view of a portion of a cable bundlepositioned within an aperture between jaws of an applicator tool ascable tie material is being wound around the cable bundle.

FIG. 3B illustrates an enlarged portion of an applicator tool as cabletie material is being wound around the cable bundle.

FIGS. 4A and 4B illustrate side views of portions of an applicator toolpositioned to ultrasonically weld a cable tie fastener in a fastenedposition about a cable bundle.

FIG. 5 illustrates a feedback control system for an ultrasonic weldingsystem according to an illustrated embodiment of the subjectapplication.

FIG. 6 illustrates a flow chart depicting an exemplary process forfastening a cable tie using an ultrasonic welding system having afeedback control system according to an illustrated embodiment of thesubject application.

FIG. 7 provides an exemplary chart depicting five power curves forpolyacetal cable ties with an energy set point of 15 Joules (J).

The foregoing summary, as well as the following detailed description ofcertain embodiments of the present application, will be betterunderstood when read in conjunction with the appended drawings. For thepurpose of illustrating the application, there is shown in the drawings,certain embodiments. It should be understood, however, that the presentapplication is not limited to the arrangements and instrumentalitiesshown in the attached drawings. Further, like numbers in the respectivefigures indicate like or comparable parts.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Certain terminology is used in the foregoing description for convenienceand is not intended to be limiting. Words such as “upper,” “lower,”“top,” “bottom,” “first,” and “second” designate directions in thedrawings to which reference is made. This terminology includes the wordsspecifically noted above, derivatives thereof, and words of similarimport. Additionally, the words “a” and “one” are defined as includingone or more of the referenced item unless specifically noted. The phrase“at least one of” followed by a list of two or more items, such as “A, Bor C,” means any individual one of A, B or C, as well as any combinationthereof.

FIG. 1 illustrates an exemplary ultrasonic welding system 100 forfastening a cable tie 102 to a cable bundle 104 according to anillustrated embodiment of the subject application. As shown, theultrasonic welding system 100 can include an applicator tool 106,ultrasonic welding generator 108, control system 110, and input/outputdevice 112. According to the illustrated example, the applicator tool106 is used to fasten or secure one or more cable ties 102 in a closedposition around a cable bundle 104, which can, for example, be used inconnection with producing a wire harness 114.

The applicator tool 106 can be electrically coupled to the ultrasonicwelding generator 108, such as, for example, via a cable 116. Further,the ultrasonic welding generator 108 can be configured to convertelectrical power provided to the ultrasonic welding generator 108, suchas, for example, low-frequency electricity (e.g. around 50 to around 60Hertz (Hz)), to high-frequency electricity, such as, for example,electricity having a frequency of around 20 to around 40 kilohertz(kHz). The high-frequency electricity can be delivered via the cable 116from the ultrasonic welding generator 108 to the applicator tool 106 foruse in ultrasonic welding procedures, such, as for, example, by theapplicator tool 106 in connection with the welding of cable tie materialof a cable tie 102. The ultrasonic welding generator 108 can also becommunicatively coupled to the applicator tool 106 such that informationregarding the welding procedure(s), including, for example, weldingsettings, parameters, and sensed or measured data or information can becommunicated between at least the ultrasonic welding generator 108 andthe applicator tool 106.

As seen in FIGS. 1 and 2 , the ultrasonic welding generator 108 and/orapplicator tool 106 can also be communicatively coupled to the controlsystem 110, such as, for example, via a wired or wireless connection(s).As seen in FIG. 2 , the control system 110 can include a controller 118having a processing device 120, and be communicatively coupled to theone or more input/output (I/O) devices 112, such as, for example, akeyboard, keypad, display, and/or monitor, as well as a combinationthereof, among other input/output devices. Additionally, the processingdevice 120 can also be communicatively coupled to a human-machineinterface (HMI) 122 of the applicator tool 106. A variety of differenttypes of processing devices can be used for the processing device 120,such as, for example, a programmable, dedicated, and/or hardwired statemachine, or any combination thereof. The processing device 120 of thecontrol system 110 can further include multiple processors, such as, forexample, Arithmetic-Logic Units (ALUs), Central Processing Units (CPUs),Digital Signal Processors (DSPs), or the like. Processing devices 120with multiple processing units may also utilize distributed, pipelined,and/or parallel processing. The processing device 120 may also bededicated to performance of just the operations described herein, or canbe utilized in one or more additional applications.

In the depicted form, the processing device 120 is of a programmablevariety that executes algorithms and processes data in accordance withoperating logic 124 as defined by programming instructions (such assoftware or firmware) stored in a memory 126 of the control system 110.Alternatively, or additionally, the operating logic 124 is at leastpartially defined by hardwired logic or other hardware. The processingdevice 120 can include one or more components of any type suitable toprocess the signals received from an input/output device 112, such as,for, and to provide desired output signals, such as, for example,signals that can provide graphical, numerical, and/or alpharepresentations, among others, on a display of the control system 110.Such components may include digital circuitry, analog circuitry, or acombination of both.

According to certain embodiments, the memory 126 can be attachable to acartridge or spool 128 containing the cable tie material 130 that will,when ultrasonically welded and trimmed from other cable tie material 130of the spool 128, form the cable tie 102. Thus, for example, the memory126 can, according to certain embodiments, comprise an electricallyerasable programmable read-only memory (EEPROM) that may containinformation that is specific to the particular cable tie material 130and the configuration of the cable tie material 130 that is containedwithin that cartridge and/or spool 128, including, for example,information regarding a weld energy set point (*Qt) and associatedlook-up tables and/or power curve profiles, among other information, asdiscussed below. Alternatively, as shown in FIG. 2 , according to otherembodiments, the memory 126 can be included with the processing device120 and/or coupled to the processing device 120. Further, the memory 126can be of one or more other types, such as a solid-state variety,electromagnetic variety, optical variety, or a combination thereof.Additionally, the memory 126 can be volatile, nonvolatile, or acombination thereof, and some or all of the memory 126 can be of aportable variety, such as a disk, tape, memory stick, cartridge, or thelike. In addition, according to certain embodiments, the memory 126 canstore data that is manipulated by the operating logic 124 of processingdevice 120, such as data representative of signals received from and/orsent to the applicator tool 106, ultrasonic welding generator 108,and/or the input/output device(s) 112, in addition to, or in lieu of,storing programming instructions defining the operating logic 124.

The controller 118 can control operation of at least portions of theapplicator tool 106 and/or the ultrasonic welding generator 108,including, for example, information and menus displayed on the HMI 122on the applicator tool 106. Additionally, according to certainembodiments, the controller 118 can be configured to control at leastcertain operations of the applicator tool 106 and/or ultrasonic weldinggenerator 108 based at least on various parameters and/or settings,which may be predetermined and/or detected or measured, including, forexample, real-time information or data that is measured or detectedduring an ultrasonic welding operation and/or attained and recorded orstored from a prior ultrasonic welding operation, as discussed below.The particular parameters and settings controlled by controller 118 canbe based on a variety of criteria, and may or may not utilizepreprogrammed and/or pre-determined parameters that may be stored in thememory 126 and/or obtained or adjusted by a feedback control system 132,as discussed below.

As shown in at least FIGS. 1 and, 3A-4B, the applicator tool 106 caninclude a first jaw 134 a and a second jaw 134 b that extend outwardlyfrom a housing 138 of the applicator tool 106. At least one of the firstand second jaws 134 a, 134 b, such as, for example, the first, upper jaw134 a, can be pivotally displaceable relative to the other jaw 134 bfrom a closed position, as seen in FIGS. 1, 3A and 4A, to an openposition, as indicated by the broken lines in FIG. 4A. When at theclosed positon, a distal end 136 a of the first jaw 134 a can be inrelatively close proximity to, if not abutting and/or overlapping, adistal end 136 b of the second jaw 134 b, thereby at least generallyclosing an aperture 140 that is generally defined by the first andsecond jaws 134 a, 134 b. As seen in at least FIGS. 1 and 3A, 4A, theaperture 140 can have a size, such as, for example, a diameter, that canaccommodate at least selective placement of at least a portion of one ormore cable bundles 104 within the aperture 140.

When the first jaw 134 a is in the open position, as indicated by thebroken lines shown in FIG. 4A, the distal end 136 a of the first jaw 134a can be separated from the second jaw 134 b by a distance that is sizedto accommodate the ingress/egress of the cable bundle(s) 104 into/fromthe aperture 140, and thus accommodate the applicator tool 106 beingselectively, and removably, positioned around the cable bundle 104.Accordingly, when the cable bundle 104 is positioned within the aperture140, the first jaw 134 a can be pivotally displaced from the openposition to the closed position, and operations relating to fastening acable tie 102 around the portion of the cable bundle(s) 104 within theaperture 140 can commence. Following the cable tie 102 being formed andsecured to, and/or around, the cable bundle(s) 104, the first jaw 134 acan again be displaced from the closed position to the open positionsuch that the cable bundle 104 can be removed from the aperture 140through the space between the distal ends 136 a, 136 b of the opposingfirst and second jaws 134 a, 134 b.

As seen in at least FIG. 2 , the housing 138 of the applicator tool 106can house a variety of components of the applicator tool 106. Forexample, according to certain embodiments, the housing 138 can at leastpartially, if not completely, house an actuator 142, such as, forexample, a manual trigger that can be engaged by a worker.Alternatively, the actuator 142 can be an automated actuator that isoperated upon receipt of an on signal, and/or deactivated upon receiptof an off signal, from the control system 110 and/or ultrasonic weldinggenerator 108.

Activation of the actuator 142 can facilitate the operation of a feedmotor assembly 144 of the applicator tool 106. According to theillustrated embodiment, the feed motor assembly 144 can include a motor,such as, for example, an electric motor, that can facilitate therotation, in a first direction, of a spool 128 containing cable tiematerial 130 for the cable tie 102. According to certain embodiments,the spool 128 can contain a generally continuous strand of cable tiematerial 130 for the cable tie 102, such as, for example,polyoxymethylene (POM), including acetal and/or polyacetal, orhigh-density polyethylene (HDPE), among other non-metallic or metalliccable tie materials 130. Alternatively, the spool 128 can contain aplurality of detachable cable ties formed from similar metallic ornon-metallic cable tie materials. The cable tie material 130 dispensedvia rotation of the spool 128 by activation of the feed motor assembly144 can be led by a guidance system 146 through the applicator tool 106,and moreover, through and/or around the housing 138, and be fed around,or in proximity to, inner surfaces the first or second jaw 134 a, 134 b.The guidance system 146 can comprise one or more guides, pulleys,rollers, and/or other devices or structures that can at least assist indirecting or guiding the passage, and/or supplement the drivingmovement, of the cable tie material 130 that is being unwound from thespool 128 and being delivered to at least the jaws 134 a, 134 b and/oraperture 140 of the applicator tool 106.

As seen in at least FIG. 3A, according to the illustrated embodiment,the cable tie material 130 fed from the spool 128 can slide and/or beguided along inner surfaces of the jaws 134 a, 134 b that are generallyadjacent to the aperture 140 so as to form one or more loops around thecable bundle 104. Moreover, according to certain embodiments, thestiffness of the cable tie material dispensed from the spool 128 canassist with the cable tie material 130 being able to move, as well as beretained, along or generally adjacent to at least a portion of the innersurfaces of the first and second jaws 134 a, 134 b as the cable tiematerial 130 is being looped around an adjacent portion of the cablebundle(s) 104 that is/are within the aperture 140 formed generallybetween the first and second jaws 134 a, 134 b. For example, accordingto certain embodiments, a leading end 148 of the cable tie material 130can pass through the guidance system 146 and along the inner surfaces ofthe first and second jaws 134 a, 134 b with other subsequent portions ofthe continuous strand of cable tie material 130 following. As seen, asthe leading end 148 completes a loop around the adjacent portion of thecable bundle 104, another, downstream portion of the strand of the cabletie material 130 can be positioned to overlap the leading end 148 of thestrand of cable tie material 130, thereby providing one loop of cabletie material 130 for subsequent forming and fastening of a cable tie 102around the cable bundle 104. Additional loops of cable tie material 130can continue to be formed, if desired, around the cable bundle 104 forthe cable tie 102 by continuing to wrap more cable tie material 130around the cable bundle 104 while the leading end 148 of the cable tiematerial 130 continues to be displaced around the cable bundle 104.

When the desired number of loops of cable tie material 130 for a cabletie 102 are positioned around the cable bundle 104, the applicator tool106 can provide a clamping force against adjacent portions of the cabletie material 130, as seen for example in FIGS. 4A and 4B. For example,as seen in at least FIG. 3B, the applicator tool 106 can includeopposing pivotal arms 150 a, 150 b, each pivotal arm 150 a, 150 b havingan arm segment 152 a, 152 b that extends in a first direct generallytoward the cable bundle 104 and/or aperture 140, and an anvil segment154 a, 154 b that is attached to a distal end of the associated armsegment 150 a, 150 b, and which extends in a second direction that isgenerally orthogonal to the first direction of the associated armsegment 150 a, 150 b. The pivotal arms 150 a, 150 b can be pivotal froma first, open position at which the associated anvil segments 154 a, 154b are generally positioned away from the cable tie material 130, asshown in FIG. 3B, to a second, closed position at which at least aportion of the anvil segments 154 a, 154 b are positioned between thecable tie material 130 and the adjacent portion of the cable bundle 104.

With the anvil segments 154 a, 154 b positioned between the cable tiematerial 130 and the adjacent portion of the cable bundle 104, a weldhorn 156 of the applicator tool 106 can be axially displaced in thedirection of the anvil segments 154 a, 154 b such that overlappingportions of the cable tie material 130 are positioned between the anvilsegments 154 a, 154 b and a tip 158 of the weld horn 156, as indicated,for example in at least FIG. 4B. According to certain embodiments, suchaxial displacement of the weld horn 156 can be facilitated by automatedrotation of a cam 164 via operation of a motor or other drive unit of aweld motor assembly 160 (FIG. 2 ) of the applicator tool 106. Forexample, according to certain embodiments, the weld horn 156 is coupledto a motor of the weld motor assembly via the cam 164 and a linkagesystem 162 comprising one or more connecting links, as seen for examplein FIG. 4A. The positioning of the anvil segments 154 a, 154 b and thetip 158 of the weld horn 156 relative to the adjacent portion of thecable tie material 130 can provide a clamping, or pinching, forceagainst the cable tie material 130 that is positioned therebetween. Asdiscussed below, the clamping force, which may be in a direction that isnormal to the cable tie material 130 that is positioned between the tip158 and the anvil segments 154 a, 154 b, that is attained via thecontrolled operation of the cam 164 can be determined and evaluated by afeedback control system 132, and the cam 164 may, if needed, besubsequently operated, based on the results of the evaluation and priorto the welding of the cable tie material 130, to either further increaseor decrease the clamping force that is being exerted against the cabletie material 130.

Such clamping force that is being exerted against portions of the cabletie material 130 can, according to certain embodiments, at least providea degree of resistance against the cable tie material 130 that can atleast assist in the removal of slack or excess cable tie material 130that is wrapped about the cable bundle 104, and moreover assist intightening the cable tie material 130 about the cable bundle 104. Morespecifically, as the tip 158 of the weld horn 156 and the anvil segments154 a, 154 b provide a clamping force against cable tie material, themotor of the feed motor assembly 144 can be operated to rotate the spool128 in a second, opposite direction that that can cause at least aportion of the cable tie material 130 to be generally be pulled back inthe direction of, and/or rewound about, spool 128, thereby tightening,or tensioning, the cable tie material 130 about the cable bundle 104.Additionally, in an effort to minimize waste, a portion of the leadingend 148 of the cable tie material 130 can be amongst, or adjacent to,the portion of the cable tie material 130 that is positioned between theanvil segments 154 a, 154 b and the tip 158 of the weld horn 156.Further, as discussed below, as such clamping force can impact thequality of the weld formed during the ultrasonic welding operation, thedegree of clamping force or pressure exerted against the cable tiematerial 130 can be evaluated by a feedback control system 132 (FIG. 5), including with respect to a predetermined clamp force set point orthreshold, in connection with at least determining, for example, whetherto commence the welding procedure or adjust the position of the tip 158and/or weld horn 156 so as to adjust the clamping force beforecommencing the welding procedure.

FIG. 5 illustrates a feedback control system 132 for the ultrasonicwelding system 100 according to an illustrated embodiment of the subjectapplication. As discussed below, the feedback control system 132 canprovide closed loop digital feedback that can be utilized to achieverepeatable weld quality. As indicated by FIG. 2 , according to certainembodiments, at least certain operations of various components of thesystem 100 in response to information provided by and/or determinedthrough use of the feedback control system 130 can be controlled by thecontroller 118.

As seen in FIG. 5 , according to the illustrated embodiment, thefeedback control system 132 can be used to determine, at least before awelding operation commences, and based on information from a digitalfeedback signal, whether the clamping force (Fclamp) that is beingexerted against the cable tie material 130 satisfies a clamping forceset point, and if not, facilitate adjustments to at least the applicatortool 106 so that the clamping force set point is satisfied. The clampingforce set point can be determined based on a variety of differentinformation, including, for example, the material composition of thecable tie material 130, and/or the size, shape, and/or configuration ofthe cable tie material 130, among other considerations. For example,according to certain embodiments, the clamping force set point can, forthe particular cable tie material 130 that is being welded, comprise arange of clamping forces that provide sufficient clamping, andassociated pressure, to attain desired weld qualities or characteristicswithout overly deforming and/or damaging the cable tie material 130.

According to certain embodiments, information regarding the clampingforce set point can be determined or obtained by the controller 118,such as, for example, from the memory 126 or a database, including, butnot limited to, a cloud based database. Additionally, the controller 118can determine, using the clamping force set point, a displacement setpoint (Δ*) for the displacement of one or more components of theapplicator tool 106 to attain a clamping force (Fclamp) that satisfiesthe clamping force set point. Such a determination(s) can includedetermining a degree of displacement one or more of the weld horn 156and/or the tip 158 of the weld horn 156, which can be lineardisplacements, and/or a rotational displacement of the cam 164 are to bedisplaced. Moreover, the displacement set point (Δ*) can correspond tothe extent one or more of such components are to be displaced to attainand/or adjust the degree of clamping force (Fclamp) being exerted by atleast the tip 158 of the weld horn 156 against the cable tie material130 so that a particular clamping force set point is attained. Forexample, according to certain embodiments, the determined displacementset point (Δ*) can be correlated to a displacement of the cam 164,including, for example, a displacement relating to angular position,degree of rotation, and/or a number of rotations of the cam 164 attainedvia operation of the weld motor assembly 160, that will correspond tothe clamping force (Fclamp) being exerted against the cable tie material130 being estimated to satisfy the clamping force set point.

The actual or estimated displacement (Δ) that is attained, such as, forexample, the distance the weld horn 156, tip 158, and/or cam 164 hasbeen displaced can be evaluated by the controller 118 in connection withdetermining whether the displacement set point (Δ*) has been satisfied.According embodiments, such a determination can include determiningwhether the estimated displacement (Δ) is within a predetermined rangeof the displacement set point (Δ*). According to certain embodiments,the distance of such actual displacement can be estimated or measured,such as, for example, via use of a sensor. Additionally, according tocertain embodiments, the determination of the degree of displacement (Δ)can also consider the current position of the tip 158, weld horn 156,and/or cam 164, which can also be estimated or measured.

If such an evaluation or comparison of the actual or estimateddisplacement (Δ) and displacement set point (Δ*) results in adetermination that the displacement set point (Δ*) has not beensatisfied, then the cam 164 can again be operated in an attempt toattain the displacement set point (Δ*). The updated actual or estimateddisplacement (Δ) can subsequently be evaluated in connection withdetermining whether the displacement set point (Δ*) has been satisfied.This process can continue to be repeated at least until the displacementset point (Δ*) is satisfied.

Additionally, in connection with, or following, determining whether thedisplacement set point (Δ*) has been satisfied, the controller 118 canalso evaluate whether the resulting clamping force (Fclamp) that isbeing exerted against the cable tie material 130 satisfies a clampingforce set point. As discussed above, according to certain embodiments,the exerted clamping force (Fclamp) can be measured, such as, forexample, using a strain gauge or piezoelectric transducer, to attain ameasured, predicted, or estimated clamping force value (collectivelyreferred to as a clamping force value). Additionally, FIG. 5 illustratesan embodiment in which the piezoelectric transducer 168 that receives apower supply voltage from a power supply 166 for welding, as discussedbelow, also, when not being used for welding, acting as a sensing unitin connection with attaining information or a measurement(s) of theclamping force values (F1, F2) indicating the level or degree of theclamping force (Fclamp) that is being exerted against the cable tiematerial 130. However, alternatively, according to other embodimentsanother, or different piezoelectric transducer or sensor can be used formeasuring or determining the clamping force value(s) (F1, F2).

Information regarding a first clamping force value (F1) can initially beevaluated to determine whether the clamping force set point issatisfied. Such an evaluation can, according to certain embodiments,occur after the displacement set point (Δ*) has been determined to besatisfied. If such an evaluation, which can comprise a comparison of theclamping force value (F1) to the clamping force set point, indicates theexerted clamping force (Fclamp) is to be increased or decreased, thecontroller 118 can determine a degree for displacement of the tip 158,weld horn 156, and/or cam 164, and subsequently transmit a signal tofacilitate rotational displacement of the cam 164 so as to obtain thisdetermined degree of displacement. Such a determination can, accordingto certain embodiments, also include changing or modifying thedisplacement set point (Δ*) that is recorded in the memory 126 ordatabase for use in future welding operations. In such an event,following operation of the cam 164, an updated, or second, clampingforce value (F2) can be attained in a manner similar to that describedabove with respect to attaining the initial clamping force value (F1).The updated the clamping force value (F2) can then be evaluated, orcompared, with respect to the clamping force set point, and adetermination can be made as to whether the clamping force set point issatisfied. If the clamping force set point is not satisfied, the processof adjusting the location of the tip 158, and thus the degree ofclamping force being exerted against the cable tie material 130, cancontinue until the clamping force set point is satisfied. Additionally,further updates, modifications, and/or refinement of the displacementset point (Δ*), as determined while seeking to satisfy, or which isassociated with the satisfaction of, the clamping force set point canalso be stored in the memory 126 or a database for use during subsequentor future welding operations. According to certain embodiments, upon atleast satisfaction of the clamping force set point, the welding processcan commence, as indicated by the change in thermal energy with respectto time (dQ/dt) shown in FIG. 5 .

During the welding procedure, changes in the state of ultrasonic weld,such as, for example, changes relating to the melting of energydirectors and/or the fusion of cable tie layers, can change theelectrical response of a transducer 168 of the ultrasonic weldinggenerator 108. Such changes in the electrical response of the transducer168 can include, for example, changes in the power, voltage, and/orcurrent draw of the transducer 168, the resonant frequency, and/or themechanical impedance of the layers of the cable tie material 130 thatare wrapped about the cable bundle 104. Thus, as discussed below, ratherthan basing the ultrasonic welding operation on the duration of timeduring which the cable tie material 130 is being ultrasonically welded,the feedback control system 132 can be configured to monitor and controlthe welding operation based on the accumulated ultrasonic energy that isdissipated, such as, for example, dissipated to the weld joint, and/orthe shape of a power curve that is being attained during the weldingoperation.

Thus, according to certain embodiments, the feedback control system 132can be configured to associate the welding operation that is to commencewith a weld energy set point (Qt*), which may be for example, be thetotal or accumulated weld energy that is to be absorbed by the weldjoint, as measured, for example, in Joules (J). Alternatively, oradditionally, the feedback control system 132 can be configured tomonitor the power curve that is being attained during the weldingoperation, and moreover control the power wave by reference to weldingpower curves that are known to be related to producing welds thatprovide the resulting cable tie 102 with particular characteristics,such as, for example, provide a particular range of loop tensilestrength, tension around the cable bundle, and/or visual appearance,among other characteristics.

For example, FIG. 7 illustrates five exemplary known power curveprofiles for cable tie material 130 comprising polyacetal, with theareas under each of the power curves corresponding to a weld energy setpoint (Qt*) that has been set for 15 Joules (J). The selection of aparticular weld energy set point, or range of weld energy set points,can, according to certain embodiments, be based on an evaluation of thecharacteristics, such as, for example, mechanical and/or visualproperties, that are attained when using a variety of different energyset points, or ranges of energy set points, for a particular compositionand/or configuration of a cable tie material 130. Further, power curveprofiles can be updated or modified during and/or after weldingoperations to reflect changes that correspond to attaining a weld thatprovides certain mechanical and/or visual properties. Moreover, suchupdating or modifications can reflect changes or machine learning thatcan further refine and improve the information provided by the powercurves, and thus improve the quality of the corresponding ultrasonicweld. As seen in FIG. 7 , according to certain embodiments, the powercurves can provide an indication of the electrical power, such as, forexample, in Watts, that is to be delivered to the transducer 168 and/ordrawn from the power supply 166 as a function of time (seconds). Theillustrated fluctuations in the power curves can be based, at least inpart, on the impact the softening and/or melting of the cable tiematerial 130 during the welding operation has on the power drawn fromthe ultrasonic welding generator 108 and/or the power drawn by thetransducer 168.

Additionally, variables that can impact attaining the weld energy setpoint (Qt*) and/or a particular power curve profile can include, but arenot limited to, one or more of at least the following: 1) variablesassociated with the ultrasonic welding generator 108, such as, forexample, amplitude, frequency, voltage, current, and/or weld time; (2)variables associated with the cable tie material 130, including, forexample, elasticity, strength, elongation at break, thermal condition,and/or heat cap; (3) the characteristics and/or settings of theapplicator tool 106, including, for example, cam position, cable tiedisplacement, motor current, weld force, and hold time; and/or (4) thegeometry of the cable tie material 130, including, for example, thecross sectional width, height, and/or energy direction height. Some ofthese foregoing variables can be time dependent, while other variablesare not time dependent. Additionally, some of these variables,including, for example, at least some of the above-identified variablesassociated with the ultrasonic welding generator 108 and applicator tool106, can be varied by, or based on, command signals from the controller118 such that the power drawn during the course of the welding operationby the transducer 168 can at least assist in attaining the weld energyset point (Qt*) and/or a particular power curve profile. Additionally,in view of the foregoing, different cable tie material 130 compositionsand/or configurations, and/or different ultrasonic welding generators108, can utilize different weld energy set points (Qt*) and/or differentclamping force set points.

Information regarding the weld energy set point (Qt*), power curve,and/or the associated clamping force set point for a particular weldingoperation(s) can be attained in a variety of different manners,including, for example, automatically inputted, sensed, or retrieved, orotherwise manually inputted by an operator, such as, for example, viathe input/output device 112 and/or the HMI 122. For example, asdiscussed above, according to certain embodiments, the spool 128 can bea cartridge that includes a memory 126 that may contain informationrelating to the weld energy set point (Qt*), power curve, and/or theassociated clamping force set point for the particular cable tiematerial 130, among other information, that is contained within thecartridge. Alternatively, according to certain embodiments, upondetection, recognition, or manual input of information regarding thecable tie material 130, information relating to the weld energy setpoint (Qt*), power curve, and/or the associated clamping force setpoint, among other information, may be attained by the controller 118,such as, for example, a memory 168 of, or which is accessible by, thecontroller 118, and/or from a database, including, but not limited to, acloud based database. Further, information regarding the weld energy setpoint (Qt*), power curve, and/or the associated clamping force set pointcan be available in a variety of different manners, including, forexample, look-up tables.

According to certain embodiments, such stored information can alsoreflect prior real-time measurements and/or machine-learned information.Such information obtained by the controller 118 can also includeinformation or settings for at least some of the above-discussedvariables associated with the ultrasonic welding generator 108 and/orapplicator tool 106, including, for example, settings relating to theamplitude, frequency, voltage, and/or current that is to be outputted bythe ultrasonic welding generator 108 and/or characteristics relating tothe ultrasonic wave that is to be provided by operation of thetransducer 168. Additionally, or alternatively, at least some, if notall, such variables may be determined by the controller 118, such as,for example via use of the information regarding the weld energy setpoint (Qt*), power curve, and/or the associated clamping force set pointattained by the controller 118 and associated algorithms.

Based at least in part on information regarding the weld energy setpoint (Qt*) and/or the selected power curve, the controller 118 candetermine or attain, such as, for example, from the memory 126 or adatabase, power supply set point information for a power supply 166,such as, for example, an AC power supply, that provides electrical powerfor the ultrasonic weld generator 108. Such power supply set pointinformation can include, for example, a power supply voltage set point(V*) corresponding to a voltage that is to be outputted by the powersupply 166, and/or which is to be provided to the transducer 168.Additionally, such power supply set point information can also include apower supply frequency set point (f*) that is to be outputted by thepower supply 166 and/or which is to be provided to the transducer 168.Again, such power supply set point information may be selected based onat least attempting to attain the weld energy set point (Qt*), and/orthe power curve profile that is known or estimated to result in the weldof the cable tie material 130 being able to provide the resulting cabletie 102 with certain characteristics, such as, for example, certain looptensile strength characteristics, among other characteristics.

As seen in FIG. 5 , the voltage (V) and high frequency signal (f)actually outputted from the power supply 166 can be transmitted to thetransducer 168 of the ultrasonic welding generator 108, including, forexample, a piezoelectric transducer. The transducer 168 can assist inconverting the electrical power provided by the power supply 166 into anultrasonic wave that can be used by the applicator tool 106 to weld thecable tie material 130 so as to at least assist in providing a closedcable tie 102 about the one or more cable bundles 104. As seen in FIG. 5, the ultrasonic wave can have both a magnitude (Δ) and a frequency (ω).

As also seen in FIG. 5 , according to certain embodiments, thetransducer 168, or other portion of the applicator tool 106, can outputinformation regarding the electrical power (P), which may, for example,be in Watts (W), that was supplied to the transducer 168, to anestimator 170 of the feedback control system 132. Additionally, oralternatively, such electrical power information provided to theestimator 170 can also include, for example, but is not limited to,electrical voltage, wattage, and/or frequency that was received byand/or used by, the transducer 168. Additionally, or alternatively, theinformation provided to the estimator 170 can provide an indication ofthe ultrasonic wave outputted from the transducer 168, including, forexample, the magnitude (Δ) and a frequency (ω) of the ultrasonic wave,among other information relating to the operation of the transducer 168.According to certain embodiments, the estimator 170 can use theinformation inputted to the estimator 170 to calculate, or derive frominformation accessible from the controller 118 and/or memory 126, suchas, for example, look up tables, an estimated weld energy (Qt). Theestimated weld energy (Qt), which can, for example, be represented inJoules (J), among other similar units of measurement, can provide anindication of the weld energy that is currently being delivered, and/orhas been, delivered to the weld. Moreover, according to certainembodiments, this weld energy (Qt) can reflect an instantaneous weldenergy that is being delivered to the weld, and/or indicate anaccumulated weld energy that has been delivered to the weld. Using thedetermined estimated weld energy (Qt), the controller 118 can comparethe estimated weld energy (Qt) with the weld energy set point (Qt*) todetermine whether the weld energy set point (Qt*) and/or whether theestimated weld energy (Qt) that has been delivered at a certain point intime indicates that the weld energy will, within a certain time period,result in the accumulated dissipated energy at the weld site satisfyingthe weld energy set point (Qt*).

According to certain embodiments, such an evaluation or comparison canbe used to determine a duration of time that the welding operation is tocontinue such that the accumulated weld energy that is delivered to theweld will satisfy the weld energy set point (Qt*). Additionally, oralternatively, the controller 118 can, based on an evaluation orcomparison of the estimated weld energy (Qt) with the weld energy setpoint (Qt*), adjust certain parameters of the welding operation,including, for example, adjust the power supply voltage set point (V*),that is sent from the controller 118 to the power supply 166, andthereby adjust the power supply voltage (V) that is to be received, ordrawn, by the transducer 168. Alternatively, rather than being employedin the current welding operation, such adjustments can be recorded, suchas, for example, stored by the memory 126 or a database, and beavailable for improving subsequent welding operations. Moreover, suchadjustments can, according to certain embodiments, be subsequentlyautomatically utilized in subsequent welding operations, therebyproviding the ultrasonic welding system 100 with a form of automaticmachine learning.

Alternatively, the estimator 170 can provide an estimate of the power,in Watts, that is being, and/or has been delivered to the transducer 168during the course of the welding operations, including, for example, atcertain times during the welding operation. Such information can be usedby the controller 118 in connection with the evaluating the currentpower dissipation with a selected power curve that had previously beenattained from the memory 126, including, for example, a power curveprofile such as that shown in FIG. 7 , as previously discussed. Based onsuch a comparison, the controller 118 may determine whether variables inthe welding operation, including, for example, variables relating to thepower supply voltage and/or frequency (V, f) supplied by the powersupply 166 should be modified so as to improve conformity with the poweras a function of time shown in the selected power curve. According tocertain embodiments, such adjustments can be utilized in the currentwelding operation. Alternatively, or additionally, such adjustments canbe recorded, such as, for example, in the memory 126 or a database.Further such stored adjustments can, according to certain embodiments,automatically be utilized in subsequent welding operations, therebyproviding the system with a form of automatic machine learning.

Additionally, other information regarding the welding operation, suchas, for example, the duration of the welding operation, the weldingparameters used for a particular weld(s), the operator, and/or thelocation at which the weld was performed, can also be recorded, such as,for example, in the memory 126 and/or a database, including, forexample, a cloud based database.

According to certain embodiments, the controller 118 can determine thatthe welding operation is completed, and thus is to cease, upondetermining that the estimated weld energy (Qt) satisfies the weldenergy set point (Qt*), which, again, can correspond to an accumulatedamount of dissipated energy. Alternatively, the controller 118 candetermine the timing of ceasing the welding operation based on anevaluation of the power curve attained during the welding operation, orinformation therein, with the selected known prior power curve profile,or information therein. Additionally, while the forgoing is describedwith respect to evaluation using either the weld energy set point (Qt*)or a power curve(s), according to other embodiments, monitoring and/orcontrol of the welding operation can utilize both the weld energy setpoint (Qt*) and power curves. For example, according to certainembodiments, the operation of the welding operation can be monitoredand/or controller based on use of information provided by a power curvein view of characteristics of a known power curve(s), while thecontroller 118 can decide that the welding operation is to be terminatedupon the estimated weld energy (Qt) satisfying an accumulated value forthe weld energy set point (Qt*). Conversely, information regarding theestimated weld energy (Qt), in view of the weld energy set point (Qt*),can be used to control and/monitor the welding operation, with thecontroller 118 determining whether the weld operation is, or has been,completed based on information provided using at least a known powercurve.

FIG. 6 illustrates a flow chart depicting an exemplary process 200 forfastening a cable tie 102 using an ultrasonic welding system 100 havinga feedback control system 132 according to an illustrated embodiment ofthe subject application. The operations illustrated for all of theprocesses in the present application are understood to be examples only,and operations may be combined or divided, and added or removed, as wellas re-ordered in whole or in part, unless explicitly stated to thecontrary.

At step 202, with the anvil segments 154 a, 154 b of the pivotal armsegments 152 a, 152 b positioned between the cable tie material 130 andthe adjacent cable bundle(s) 104, the cam 164 can be rotated viaoperation of the motor of the weld motor assembly 160 such that the tip158 of the weld horn 156 is positioned, or advanced, against theadjacent cable tie material 130. Moreover, as discussed above, the weldhorn 156 and associated tip 158 can be generally linearly displaced atstep 202 such that a clamping force is exerted against at least aportion of the cable tie material 130 that is positioned between the tip158 of the weld horn 156 and the anvil segments 154 a, 154 b of thepivotal arm segments 152 a, 152 b. Additionally, as also discussedabove, according to certain embodiments, the extent to which the tip 158of the weld horn 156 is displaced, and/or the associated displacedposition of the weld horn 156 and/or tip 158, may be based on thedisplacement set point (Δ*) and the associated clamping force value (F1,F2, . . . Fn) that is to be attained from such displacement.

At step 204, upon the weld horn 156 and/or tip 158 reaching thedisplaced position, a determination can be made as to whether theclamping force (Fclamp) that is being exerted against the cable tiematerial 130 satisfies the clamping force set point. Again, such anevaluation can include attaining a clamping force value (F1), such as,for example, via use of a piezoelectric transducer and/or strain gauge,among other sensors. Further, while the determination of whether thecurrent clamping force being exerted against the cable tie material 130does, or does not, satisfy the clamping force set point can bedetermined by a variety of components of the ultrasonic welding system100, according to the illustrated embodiment the determination can bemade by the controller 118 of the control system 110.

If at step 204 a determination is made that the clamping force value(F1) corresponding to the clamping force that is currently being exertedagainst the cable tie material 130 does not satisfy the clamping forceset point, then the process can return to step 202, and a signal orinstruction can be communicated to again operate the motor of the weldmotor assembly 160 in a manner that can facilitate operation of the cam164. Moreover, in the event the clamping force being exerted against thecable tie material 130 is to be increased, the motor of the weld motorassembly 160 can be operated in a manner that causes the cam 164 torotate in a direction that can further generally linearly displace thetip 158 of the weld horn 156 in a direction of the cable tie material130 and/or the anvil segments 154 a, 154 b of the pivotal arm segments152 a, 152 b that are positioned behind the cable tie material 130. Suchrotation of the cam 164 and associated displacement of the tip 158 ofthe weld horn 156 can continue until the tip 158 reaches anotherposition, or a degree of displacement of the cam 164, tip 158, and/orweld horn 156 is attained, that can correspond to a location at whichthe clamping force value (F2) associated with the current clamping force(Fclamp) that is now being exerted against the cable tie material 130 ispredicted, estimated, and/or detected to satisfy the clamping force setpoint. This process of operating the cam 164 to adjust the clampingforce on the cable tie material 130 can continue until the clampingforce set point is satisfied.

Evaluation of whether the clamping force value (F1, F2, . . . Fn)satisfies the clamping force set point can include determining whetherthe clamping force value (F1, F2, . . . Fn) is lower than, or exceeds,the clamping force set point, or an associated range for the clampingforce set point. Thus, for example, the process at step 204 can involvedetermining whether the clamping force being exerted against the cabletie material 130 is excessive such that degree of the current clampingforce currently being against the cable tie material 130 should bereduced. In the event a determination is made that the clamping forcecurrently being exerted against the cable tie material 130 is excessive,the process can return to step 202, during which the motor of the weldmotor assembly 160 can be operated in a manner that causes the cam 164to rotate in a direction that can displaces the tip 158 of the weld horn156 in a direction generally away from the cable tie material 130 and/orthe anvil segments 154 a, 154 b of the pivotal arm segments 152 a, 152 bthat are positioned behind the cable tie material 130. Such rotation ofthe cam 164 and associated displacement of the tip 158 of the weld horn156 can continue until the tip 158 reaches another position that cancorrespond to a location at which the clamping force being exertedagainst the cable tie material 130 can satisfy the clamping force setpoint.

At step 206, upon satisfaction of the clamping force set point, theultrasonic welding of the cable tie material 130 can commence. Asmentioned above with respect to FIG. 5 , during such welding, thefeedback control system 132 can be used to monitor whether the estimatedweld energy (Qt) is, or is not, satisfying the weld energy set point(Qt*). As also previously discussed, during step 206, in the event theweld energy set point (Qt*) is not being satisfied, the controller 118can make adjustments to the welding operating, including, for example,adjustments to the weld set point information so as to at least attemptto satisfy the weld energy set point (Qt*). Additionally, suchadjustments can be stored and implemented into subsequent weldingprocedures, which can refine the welding operation and improve thequality and repeatability of subsequent welding of cable tie material130.

As also seen in FIG. 6 , at step 208, the controller 118 can monitor ifthe weld has been completed, and, if not completed, continue with thewelding operation. Such a determination can, according to certainembodiments, include determining whether the accumulated ultrasonicenergy that has been dissipated to the weld joint as satisfied theenergy set point (Qt*) and/or whether a particular power curve has beenattained.

At step 210, upon a determination by the controller 118 that that theweld has been completed, the applicator tool 138 can cease welding thecable tie material 130, and the cable tie material 130 can be given anopportunity to cool off. Such cooling can provide for the temperature ofthe weld to be reduced to a level that can prevent inadvertent damage tothe newly formed weld. Such a period of cooling may also include timefor the cable tie material 130 to be cut or trimmed, such as, forexample, by use of a strap cutter 172 of the guide system 146, fromother portions of the cable tie material 130, thereby detaching theformed cable tie 102 from the cable tie material 130 that remainscoupled to the spool 128. The first jaw 134 a of the applicator tool 106can also be moved to the open position, as indicated by the broken linesshown in FIG. 4A, and the cable bundle 104 with the newly formed cabletie 102 can be moved away from applicator tool 106, or vice versa.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment(s), but on the contrary, is intended to covervarious modifications and equivalent arrangements included within thespirit and scope of the appended claims, which scope is to be accordedthe broadest interpretation so as to encompass all such modificationsand equivalent structures as permitted under the law. Furthermore, itshould be understood that while the use of the word preferable,preferably, or preferred in the description above indicates that featureso described may be more desirable, it nonetheless may not be necessaryand any embodiment lacking the same may be contemplated as within thescope of the invention, that scope being defined by the claims thatfollow. In reading the claims it is intended that when words such as“a,” “an,” “at least one” and “at least a portion” are used, there is nointention to limit the claim to only one item unless specifically statedto the contrary in the claim. Further, when the language “at least aportion” and/or “a portion” is used the item may include a portionand/or the entire item unless specifically stated to the contrary.

The invention claimed is:
 1. A method comprising: determining if aclamping force being exerted by a tip of a weld horn of an applicatortool on a portion of an object that is to be ultrasonically weldedsatisfies a clamping force set point, wherein a sensor measures theclamping force exerted against the portion of the object by the weldhorn; attaining a weld energy set point for the ultrasonic welding ofthe object, the weld energy set point corresponding to an accumulatedenergy that is to be dissipated at a weld site of the ultrasonic weld;commencing, after satisfaction of the clamping force set point,ultrasonic welding of the object, an ultrasonic weld generator providingan ultrasonic wave to the applicator tool for the ultrasonic welding ofthe object; estimating the weld energy delivered to the weld site; andceasing the ultrasonic welding of the object after the estimated weldenergy satisfies the weld energy set point.
 2. The method of claim 1,further comprising determining a displacement set point, thedisplacement set point being an estimate of an extent at which at leastone of the weld horn, the tip, and a cam of the applicator tool is/areto be displaced to result in the clamping force satisfying the clampingforce set point.
 3. The method of claim 1, wherein the step ofdetermining if the clamping force satisfies the clamping force set pointcomprises: determining, using a piezoelectric transducer of theultrasonic weld generator, one or more clamping force values, the one ormore clamping force values corresponding to the clamping force beingexerted on the object; and comparing the one or more clamping forcevalues to the clamping force set point.
 4. The method of claim 1,further comprising retrieving, by a controller of a control system, atleast one of the clamping force set point and the weld energy set pointfrom a memory that is coupled to a spool that contains or contained theobject, the spool being selectively attachable to the applicator tool.5. The method of claim 1, wherein the object is cable tie material. 6.The method of claim 1, further including determining, using the weldenergy set point, a voltage set point and a frequency set point forelectrical power that is to be drawn by the ultrasonic weld generatorfrom a power supply, and wherein the weld energy is estimated, at leastin part, based on a voltage and a frequency of the electrical power thatis drawn by the ultrasonic weld generator from the power supply.
 7. Themethod of claim 6, further comprising: determining if the weld energydoes, or is on target to, satisfy the weld energy set point;determining, by a controller in response to the determined weld energynot satisfying, or not being on target to satisfy, the weld energy setpoint, an adjustment for at least one variable of at least one of theultrasonic weld generator and the applicator tool; and recording theadjusted at least one variable for use in subsequent ultrasonic weldingoperations.
 8. The method of claim 7, further including the step ofadjusting the at least one variable during the current weldingoperation.
 9. The method of claim 7, wherein the at least one variablecomprises at least one of the voltage set point, the frequency setpoint, a magnitude of the ultrasonic wave, and a frequency of theultrasonic wave.